Manufactured standard size dwellings having an integral base frame

ABSTRACT

The movable manufacturing facility brings standard size home building comprehensively within a controlled factory environment. The main structure of the movable manufacturing facility is sufficiently tall to allow assembly and movement of standard size homes within. Multiple independent production lines are established to each produce portions of the dwelling in the form of subassemblies. Finishes, cabinets, appliances, roofs, paint, etc. are installed in the partially completed dwellings prior to houses leaving the production floor. The movable manufacturing facility allows a standard size home under construction to be advanced via a transport element from one production line to the next until complete. The completed homes are subsequently transported on the transport element over a controlled access roadway to individual sites with pre-constructed foundations specifically designed to accept these standard size dwellings. The standard size house can be relocated from the transport element and placed directly onto the foundation. High capacity hoisting, such as clear span bridge cranes, are the key to material handling and transportation on the production lines in the movable manufacturing facility. A drive through alley large enough to accommodate semi-trucks with loaded trailers may be located within the main structure of the movable manufacturing facility.

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is a divisional of U.S. patent application, Ser.No. 08/970,231, filed on Nov. 14, 1997, which is related to anapplication titled “Method of Production of Standard Size DwellingsUsing a Movable Manufacturing Facility” filed on Nov. 14, 1997.

FIELD OF THE INVENTION

[0002] This invention relates to a movable manufacturing facility thatcan be erected near a large housing development to efficientlymanufacture standard size dwellings, substantially in their entirety, ina factory environment prior to transporting and placing these completeddwellings on pre-constructed permanent foundations. These standard sizedwellings, as defined herein, have an abundance of architectural andfloor plan flexibility, high volume rooms and, typically, living areasof 1,600 square feet or more on one or two levels, not includingbasements.

BACKGROUND OF THE INVENTION—THE HOUSING INDUSTRY TODAY

[0003] The present residential construction industry can be divided intosegments based on the three basic methods which are utilized to producedwellings: manufactured or modular (manufactured), panelized orcomponent (panelized)—with elements fabricated both on and off site, andindividually built (stick-built)—with dwelling construction in-place ata specific building site. Each of these three methods have distinctadvantages and disadvantages. In addition, each method is suited toproduce a particular type of dwelling. A common goal of the residentialconstruction industry is to produce quality dwellings that have broadmarket appeal in a cost efficient manner.

[0004] The manufactured home is built in a factory which isgeographically remote from a housing development or a particularbuilding site. The factory produced modules must be transported overpublic highways and roadways to a dealership or pre-determined buildingsite. The earliest of this class of homes were called mobile homes. Theywere, and still are, equipped with axles attached to an undercarriageframework. The typical manufactured home is built in a factory whichserves a broad geographic region, ranging in size from tens or hundredsof miles in radius to several states. Because of the cost efficienciesinherent in factory production, the manufactured (and some panelized)method is successful in producing lower cost new housing typically forsmall size homes. A manufactured home is produced for direct sale to acustomer and installation at a particular building site or it may besold to a dealer and held in inventory for a subsequent sale andinstallation.

[0005] The present day manufactured home offers significant improvementsover the former mobile home. A plurality of manufactured modularsegments may comprise the finished home and the modules are transportedfrom a remote factory to a dealership or destination building site. Oncedelivered to the final building location, the modules are joinedtogether to form a resultant dwelling that is significantly larger thana typical 12′×70′ single module manufactured home.

[0006] The major advantage of manufactured homes is the use of a factoryenvironment. Within a factory setting, a controlled environment existswhere complete, roadable dwellings are built. Factories represent asignificant advantage in mass production efficiency. The advantages of afactory environment are:

[0007] Dwellings can be produced very quickly from order to finishedproduct. Foul weather has negligible impact on production.

[0008] Construction tolerances are more precise and more controllable.

[0009] Increased production through multiple shifts is readilyachievable because the critical conditions of lighting, ventilation andair temperatures are controlled 24 hours a day.

[0010] Non-sequential construction techniques are possible.

[0011] A Federal (HUD) Building Code can be utilized which offers astreamlined regulatory environment since it is focused on performancestandards rather than implementation standards. In addition, homes builtto the HUD Building Code are less expensive to produce than stick-builthomes which are built to the Uniform Building Code (UBC) or other localbuilding codes.

[0012] Major cost efficiencies are realized in both the quantity oflabor hours necessary to build homes, and the unit cost for laborbecause of the use of repetitive production tasks and the ability tobulk purchase and handle materials at a fixed manufacturing location.

[0013] A method of dwelling construction which has similarities to themanufactured dwelling technology is the panelized method ofconstruction. Panelized construction consists of a system forprefabricating walls, floors and roof components into units or sections.This method of construction is most efficient where there is arepetition of the panel types and dimensions. Panels are manufacturedusing a jig, into which the framing members are placed and theninterconnected via nails, screws or welds. The interior and exteriorsheathing, or even the complete interior or exterior finish, may beapplied to the wall panel prior to the finished panel being hoisted ontothe structure. Shop panelization offers numerous advantages. The panelshop provides a controlled environment where work proceeds regardless ofweather conditions. The application of sheathing and finish work iseasier and faster with the panels placed in a horizontal positioninstead of a vertical position.

[0014] With panelized construction, major components of homes are eitherprefabricated in a remote factory environment or at the site where,unfortunately, panel fabrication is exposed to local weather conditions.If components or panels are built in a factory, they are subsequentlytransported over public highways and roadways to the building site wherethey are hoisted into place and interconnected to form the basicdwelling structure using conventional building techniques. The panelizedconstruction technique requires the use of hoisting equipment at thebuilding site to handle the preassembled components and also requiresthat significant amounts of finish work be performed at the site toassemble components and finish construction joints between panels.

[0015] The major advantages of panelized construction are the following:

[0016] Cost and production efficiencies of off-site factory panelfabrication.

[0017] Efficiencies of mass producing panels at a project location canalso be realized.

[0018] Assembly of panels or components into finished homes isreasonably fast.

[0019] Pre-fabricated panels for production of homes in “remote” regionscan be accomplished.

[0020] The remaining category of residential housing is the stick-builthouse that is either custom built according to an owner's individualspecifications, or as a builder's spec home, or constructed as one of aplurality of pre-existing models in a housing development. Thesedwellings are built in the traditional manner of using framing members(typically dimensional lumber) to fabricate the dwelling on a foundationat the building site according to a set of architectural plans.Stick-built home design differs greatly from manufactured home design.There are no architectural, structural or dimensional limitations withstick-built housing like those imposed on manufactured design by virtueof the roadway transportation limitations. Transportation over publicroads involves height, width, length and weight restrictions. Instick-built construction, height, width, depth, roof pitch, roofoverhang, gabled, dormered, etc. are all completely open to individualtastes limited only by the governing building code restrictions. Theability to produce standard size homes with substantial designflexibility is the reason that the majority of homes built today arestick-built homes.

[0021] Stick-built construction requires a sequenced building format,where item A must be completed before item B can begin, and in turn,item B must then be completed before item C can begin and so on. Forexample, the ground level walls must be completed before the secondlevel floor can begin, and the second level walls must be completedbefore the second level ceiling can begin. While this method ofresidential home construction has worked for many years, there areinherent inefficiencies in this method that result in significant costpenalties to the home buyer.

[0022] Stick built dwellings can be built to any size or layout that isdesired within the limitations of the structural capabilities of theframing material. Multi-story homes can easily be built with thearchitectural features, room size and layout being determined by thearchitect, home builder and/or owner. There are no overridingconstraints imposed by a need to transport the structure over theexisting public highway or roadway system.

[0023] Other advantages of stick-built construction techniques are:

[0024] Ability to build a wide diversity of standard size dwellings(including single and multi-story).

[0025] Individual customization is easy.

[0026] Well known and widely accepted method of construction.

[0027] Skilled subcontractors are generally available.

[0028] Thus, it is evident that each of the above-noted methods ofresidential dwelling construction have certain distinct advantages,which advantages are typically intimately coupled with the type ofdwelling produced by the selected method of construction.

[0029] Problem—Manufactured Construction Methods

[0030] While manufactured, panelized and stick-built homes have manyadvantages in their respective market applications, each of them alsohas distinct disadvantages. These disadvantages form the core problemswhich face the housing industry today and, in particular, for themanufactured method:

[0031] Dimensional and design constraints have confined manufacturedhomes to a limited market segment.

[0032] The manufactured method cannot be used to build standard sizehomes without segmentation of the home into modules of relatively smalldimensions which results in design and floor plan compromises.

[0033] The manufactured modules must be transported a significantdistance from the factory to the building site, often via a dealership.

[0034] Manufactured home segments are subject to significantarchitectural and floor plan constraints because of the need totransport the completed modules over public highways and roadways.

[0035] There are significant size limitations in manufactured homes:single-story, 10-14 ft wide by 50-70 ft long with box-like architecture.

[0036] The cost of field mating the roadable manufactured modules andrelated field quality control necessary for assembly and finishing canbe significant.

[0037] There is a possibility for damage to manufactured home modulesduring extended transport over the public highway system.

[0038] Problem—Panelized Construction Methods

[0039] There are also problems with panelized constructed homes:

[0040] Field labor is required for field assembly of panels.

[0041] Less than complete dwelling units are produced, since it is amethod to produce only segments of homes.

[0042] The panelized method of construction cannot build standard sizehomes without segmentation of the home into modules of relatively smalldimensions which results in many compromises.

[0043] The panels or components that are manufactured require majorfield assembly which takes a significant amount of time and aretherefore exposed to local weather conditions.

[0044] The panels built in a remote plant have size limitations becauseof the necessity to transport these panels over public highways androadways.

[0045] The panels must be assembled at the project site, andconstruction joints between the panels must be repaired and finished atthe project site.

[0046] Major design constraints exist because panels must be roadable.

[0047] There is a possibility for damage to panels and components duringextended transport and handling.

[0048] Problem—Stick-Built Construction Methods

[0049] There are also problems in the stick-built method of dwellingconstruction:

[0050] Stick-built construction is inherently a sequential home buildingprocess—floors are built before walls, walls before ceilings and theroof after all the other framing is completed. This is a lengthy processand therefore results in construction activity of extended duration.

[0051] Much of the work done in stick-building a dwelling is at themercy of local weather conditions which can delay schedules and damagematerials.

[0052] Bulk material delivery and handling are not possible because thematerials need to be segregated for each individual home.

[0053] The materials and supplies are mostly hand carried,piece-by-piece, into and within the house during construction.

[0054] It is common to have 4 to 10 month construction schedules instick-built construction of a dwelling.

[0055] Homes must conform to the local building codes, such as theUniform Building Code (UBC), without any ability to build to the Federal(HUD) Building Code which would be faster, less expensive, and providean easier regulatory environment.

[0056] The cost of labor in stick-building is high to thereby attractthe necessary skill levels to widely scattered job sites.

[0057] Supervision and quality control in stick-building is non-uniform.

[0058] A significant disadvantage of the stick-built dwellingconstruction technique is that regardless of the size and/or complexityof the dwelling, these homes are built according to a process that isdetermined by both building codes and the need for efficiency of thevarious independent subcontractors that are engaged to construct thedwelling. In particular, each subcontractor wishes to minimize thenumber of times that he must visit the building site and often prefersunobstructed access to the majority of the structure with limitedinterference or coordination with other subcontractors. Thisconstruction process, especially early on, is highly dependent onweather conditions and can only occur during daylight hours. Aninterruption in the flow of construction caused by one of thesubcontractors has a ripple effect in that the other subcontractors mustawait the completion of a particular task before they can begin theirwork. Therefore, while each individual subcontractor task does notnecessarily take a lot of time in constructing a stick-built residentialdwelling, the time intervals between the arrival of the varioussubcontractors and delays occasioned by weather and other subcontractorwork, significantly lengthens the amount of time required to completeeach dwelling. Furthermore, operating in a field environment isdetrimental to maintaining the quality of the construction since it isdifficult using portable hand tools to precisely cut and assembleframing material into walls and various finish elements with precisetolerances. It is often difficult in stick-built home construction tofind a sufficient number of skilled workmen who can craft a residentialstructure of high quality at very reasonable costs. The quality suffersand there is also a significant amount of waste, since the materialsmust be handled at least 2-3 times between shipment from the factory ormill to being delivered to the individual job site. There is excesslabor and significant breakage as a result of this repetitive handlingof materials. In addition, typically there aren't people at individualjob sites all day to receive materials so materials and supplies areexposed to the possibility of theft and bad weather. Surplus materials,unless they represent a significant quantity, are discarded since thevalue of salvaged materials does not offset the cost involved to salvagethese materials.

[0059] While the stick-built residential structure is the most desirableresidence for consumers because of the design flexibility, the costbenefits obtained by the factory manufacturing environment areunavailable to this type of construction method due to the size and moreoften than not multi-story nature of these structures.

[0060] Solution

[0061] The above described problems are solved, and a technical advanceis achieved, by the movable manufacturing facility of the presentinvention, which is capable of efficiently producing standard sizedwellings in a factory environment.

[0062] The movable manufacturing facility of the present invention,responds to the fundamental desire to maximize home building efficiencyby implementing both a factory for and a method of full size dwellingconstruction that is of novel design. The movable manufacturing facilityis capable of producing standard size dwellings and supplying them to anew community in a cost effective and time efficient manner unlike anyconstruction method of the prior art. The reason this facility is termed“movable manufacturing facility” is that, at the end of a given project,the main structure of the movable manufacturing facility may bedisassembled and transported to a new community development or remain inplace and revert to a secondary use, such as a warehouse or fitnesscenter. The movable manufacturing facility not only overcomes theproblems inherent in the construction methods of the prior art, but alsocombines the advantages of the three methods of dwelling constructionidentified previously. Homes produced within the movable manufacturingfacility appear to the consumer to be identical to stick-built standardsize homes. These homes have substantial design and architecturalflexibility, high volume rooms, modern floor-plans and significantoverall living space. The homes that can be produced utilizing themovable manufacturing facility are unlike any manufactured homesproduced today. These homes may include a wide diversity of standardsize one and two story single family dwellings or various forms ofmulti-family dwellings.

[0063] The movable manufacturing facility is implemented specificallyfor the construction of individual new communities. The communitiesportrayed in this text exemplify housing needs and market demand in theUnited States. The movable manufacturing facility, however, has broadapplication worldwide. The main structure, equipment and systemscomprising the movable manufacturing facility are designed to be packedinto cargo containers. These cargo containers can then be shippedanywhere in the world that is accessible by ship, rail or semi-truck. Ifthe native foreign lands don't have the essential materials and suppliesto build houses, those items can also be shipped from any supplyingnation directly to the location of the movable manufacturing facility.If by sea, containers can be off-loaded onto semi-trucks or rail cars,whichever can most efficiently and economically deliver directly to themovable manufacturing facility. There are no intermediate stops andtherefore, no associated middlemen.

[0064] A major attribute of the movable manufacturing facility is itsability to build a huge diversity of dwelling products. The only thingrequired is a community of sufficient size to amortize the cost of themovable manufacturing facility. This flexibility is essential forinternational applications because housing design and requirements arevastly different from one region to the next. A common ingredient isthat most often in bulk housing requirements, high quality, low costhomes that can be built in a timely fashion are in demand. The movablemanufacturing facility uniquely satisfies this demand.

[0065] The movable manufacturing facility also has the versatility tobuild homes either with dimensional lumber or steel framing. Althoughthe idea of steel may conjure up an image of a heavy or cumbersomematerial, the steel that is used in residential construction is just theopposite. Cold-formed, high strength, light gauge steel is light-weight,easy to handle, cost effective and a high quality alternative totraditional residential framing materials. Steel offers a strong,dimensionally stable, easy-to-work framing system. Steel members weighas much as 60% less than wood members, therefore, foundation and evenseismic loads for a dwelling can be reduced. Because of its strength,steel can span greater distances, offering larger open spaces andincreased design flexibility without requiring intermediate columns orload bearing walls. In addition, steel framing accommodates all types ofcommonly used finished materials. Steel does not rot, shrink, swell,split, or warp, and is non-combustible. All steel products arerecyclable. Framing members are manufactured with pre-punched holes forrunning piping and electrical wiring, minimizing preparation work forother trades.

[0066] In recent years, with the rapid escalation of lumber prices,builders have discovered that framing with steel can be less expensivethan framing with lumber. While the price of traditional framingmaterials has been erratic and growing at a rate much faster thaninflation, steel prices have typically only experienced small quarterlyadjustments. There is a strong likelihood that steel framed houses willplay a dominant role in the production of residential building productsin the next ten years. Presently, steel is primarily used as astick-for-stick substitute for wood, meaning that it is simply adifferent material used in identical methods to wood studs. Steelobviously has much more potential than this. One logical progressionincorporated into the movable manufacturing facility is that steelframing studs can be continuous for two stories in house framing design.This opportunity decreases labor and materials costs while reducingoverall construction time as well. Steel studs of 20 foot length arerelatively easy to work with and cost effective, while this type offraming is not at all practical in wood due to the inherent length andstability limitations of lumber materials. The two story steel framewall assemblies are used in balloon-type framing which includes integralcross-bracing to increase the shear strength of the wall subassembly inthe plane of the wall surface. This strapping and bracing virtuallyeliminates racking of the wall subassembly, thereby resulting in adwelling that is structurally more sound than one constructed usedexisting techniques.

[0067] The movable manufacturing facility is not implemented for thegeneral manufacturing of homes to be shipped to a broad geographicregion like the prior art manufactured and panelized systems. It is aspecialized movable manufacturing facility erected proximate to alocation where a large number of dwellings are to be built. The movablemanufacturing facility may be linked to this community via a controlledaccess roadway, where public access can be limited and where width andheight impediments may be much less restrictive than public streets. Asa direct result, the primary problem involving the constraints of thepublic roadway infrastructure that lie between the factory and thebuilding site for shipment of manufactured or panelized products isovercome. The movable manufacturing facility brings the factory to thebuilding site. This opens the door to a whole new world of design andconstruction methodologies for factory produced homes. The overwhelmingconstraints imposed on home design, size, transportation concerns, etc.due to public roadway transport limitations between a remote factory andthe final home site are eliminated.

[0068] The movable manufacturing facility brings standard size homebuilding comprehensively within a controlled environment. The mainstructure of the movable manufacturing facility is sufficiently tall (30to 40 feet) to allow assembly and movement of standard size homeswithin. Multiple independent production lines are established to eachproduce portions of homes. Materials and supplies can be purchased andhandled by the semi-load within the movable manufacturing facility.Production lines exist within the movable manufacturing facility, eachbuilding and assembling different components for the finished housingproduct. All finishes, cabinets, appliances, roofs, paint, etc. areinstalled in the partially completed dwellings prior to houses leavingthe production floor. The movable manufacturing facility allows astandard size home under construction to be advanced via a transportelement from one production line to the next until complete. Thecompleted homes are subsequently transported on the transport elementover a controlled access roadway to individual sites withpre-constructed foundations specifically designed to accept thesestandard size dwellings. The standard size house can be relocated fromthe transport element and placed directly onto the foundation.

[0069] High capacity hoisting, such as clear span bridge cranes, are thekey to material handling and transportation on the production lines inthe movable manufacturing facility. A drive through alley large enoughto accommodate semi-trucks with loaded trailers may be located withinthe main structure of the movable manufacturing facility. This promoteshighly efficient unloading and subsequent material handling directlyfrom bulk truck shipments to the production lines or storage areas viathese high capacity hoists. The hoists can also place large rolls ofcarpeting, appliances, cabinets and the like directly inside thepartially manufactured house to eliminate excess labor. Large single ormultiple story wall panels, floor assemblies, large roof assemblies,etc. can be constructed and handled in a production setting. This is notpossible with the construction methods of the prior art, principallybecause the factory environments are separated by public roadways.Finished components from the production lines can also be lifted fromthe assembly area and set directly at each components final destinationin the partially completed house with the hoisting system.

[0070] The homes to be produced using the movable manufacturing facilityhave special design characteristics. One example is an integral baseframe comprising a structural base element located at the perimeter ofeach home, and at the base of load bearing interior walls, whichstrengthens and stabilizes these standard size homes for manufacturing,transportation, placement on foundations and long-term durability. Oneimportant feature of the movable manufacturing facility is that thesequential building process necessary with the prior art of stick-builtmethods for producing standard size homes is now obsolete. The movablemanufacturing facility promotes the concurrent assembly and constructionof multiple facets of standard size dwellings: floors, walls, roofs,etc. can be built simultaneously. Construction time for standard sizedwellings is shortened from the current methods of 4-10 months to the4-25 working days achievable in the movable manufacturing facility.Further, the HUD Building Code utilized for factory producedmanufactured housing may be utilized for standard size dwellingsproduced by the movable manufacturing facility which is another uniqueand cost savings characteristic. The conformation of the resultantstructure to HUD building codes may obviate the need to deal with theplethora of local building inspectors and the inconsistent applicationof the building codes that they bring to the building process, since theHUD inspections certify that the product and process meet the HUDstandards. The HUD building codes also permit the use of innovativeconstruction techniques. These innovative construction techniquestypically represent significant cost savings to the builder.

[0071] The configuration of the movable manufacturing facility in thepreferred embodiment of the invention disclosed herein is a plurality ofparallel oriented, juxtaposed production lines that are orthogonal to,and extend between, two parallel oriented and bounding “alleys,” all ofwhich are inside this very large movable manufacturing facility. Each ofthe production lines produces a large portion, if not substantially all,of a predetermined volumetric section or subassembly of the dwelling. Anatural progression of the construction proceeds as the partiallycompleted structure advances through this first orthogonal “dwellingassembly alley” from production line to production line. The second“delivery alley” is used for the delivery of raw materials via rail ortruck into the confines of the movable manufacturing facility. Many, ifnot all of the production lines, include one or more hoisting elements,such as clear span bridge cranes that are integral to the movablemanufacturing facility. These hoisting elements are used to transportbulk quantities of raw materials from the delivery vehicles, be thatrail or truck, to storage areas that are integral to that productionline and other storage facilities within the movable manufacturingfacility, and to handle sub-assemblies in the production lines and fromproduction line to each partially completed house.

[0072] Construction of each dwelling is initiated in the first of theorthogonal alleys, the dwelling assembly alley, which is of sufficientdimension to accommodate a standard size house, when assembled therein.A integral base frame, built in the first production line, is placed ona transport element at the intake portion of the movable manufacturingfacility. This enables the dwelling, as it completes assembly at eachstage of the movable manufacturing facility, to simply advance to thenext production line in the movable manufacturing facility andultimately be transported from the movable manufacturing facility to apermanent site in the vicinity of the movable manufacturing facility.The dwelling is produced on this rigid or rigidized integral base framethat substantially circumscribes the perimeter of the dwelling, andwhere necessary, bridges the various cross-sections thereof. Thisprovides sufficient support to enable the entirety of the completeddwelling to be moved from a transport element onto a foundation at thebuilding site selected for the dwelling.

[0073] The standard size dwellings produced in this movablemanufacturing facility represent significant advances from what isproduced by the housing industry today. It is achieved by collapsing thetraditional sequential building process into a small finite number ofsteps, each of which is implemented in a predetermined production lineof the facility somewhat independent of, yet in close coordination with,the building activity that takes place in the other production lines ofthe facility. This allows, for instance, a house's roof and floor to beassembled at the same time, yet on different production lines. Onceindividual components are pre-assembled, they are affixed, eitherdirectly or indirectly, to the rigidized integral base frame as itadvances through the dwelling assembly alley. This final assembly of thehousing components occurs in a very short period of time. Quality isassured by virtue of a controlled work environment within the movablemanufacturing facility, factory tolerances, a streamlined, repetitivelabor task assembly process, etc. The sequential, mutually exclusive anddisjunct subcontractor operations of the prior art are replaced with apartitioning of the construction process to functionally complete theconstruction of predetermined volumetric sections of the structure ateach of the production lines as the dwelling progresses through themovable manufacturing facility. Thus, wall sheathing and finishing maybe started earlier than in the traditional stick-built building processwhile some operations, such as electrical and plumbing, can be done fromthe exterior of the dwelling when interior walls are in place. Eachdwelling exits the movable manufacturing facility as a substantiallycompleted “turn key” standard size dwelling ready for occupancy. Theseexamples are indicative of a streamlined and efficiency driven approachto dwelling construction, which makes use of a factory environment torevolutionize the dwelling construction process for standard size homes.

[0074] Significant time savings can be attained since this operation isweather independent and large subassemblies can be produced, and thenmoved with the plurality of hoisting devices that are an integralportion of the movable manufacturing facility. Additionally, because ofthe large number of houses being produced utilizing the movablemanufacturing facility, significant material cost savings are realizeddue to an ability to bulk purchase materials and supplies directly frommanufacturers without mark-ups to middlemen. Since shipment is alsodirect from the manufacturers to the movable manufacturing facility,there is far less breakage and damage losses because material handlinghas correspondingly been reduced. Labor savings are achieved by thehoisting devices which enable a worker to move large quantities of rawmaterials from the delivery vehicles that drive through the movablemanufacturing facility to storage areas integral to the production linesand hence into the shell of each dwelling being assembled. Thus, ifthere are N production lines in the movable manufacturing facility, Ndwellings can concurrently be in the process of being assembled. Theentirety of the manufacturing operation is executed within theenvironmentally controlled volume that is encompassed by the exteriorshell of the movable manufacturing facility. The use of precision tools,preformed jigs, substantial hoisting devices and hydraulic assembliesare justified and cost-effective since large numbers of qualitydwellings are being produced in a short time frame.

[0075] In order for construction to occur at this rapid pace, it isbeneficial to have a fully integrated computer system. This computersystem assists in the management of the tasks: purchasing, inventory,design, design changes, material take-off's, accounting, wordprocessing, etc. With Computer Aided Design (CAD) capability, plans andplan changes can be electronically transferred directly to theproduction lines while automatically calculating revised materials listsand required inventory. Present inventories along with required stockingof materials and supplies for houses in the queue can effectively beaccomplished using a CAD system. As each lot in the development is soldand the home buyer defines the model of the home to be placed thereonwith the specific customized changes desired by the buyer, thisinformation can be forwarded to the manufacturing facility where acomputerized control system can schedule the construction of thisstructure, orders and coordinates the delivery of all necessarymaterials and, during the assembly phase of the structure, providesdisplay information to the workers at each stage of the assembly processto indicate the specifics of this structure as defined by the initialuser-provided order.

[0076] The work stations in the production lines of the movablemanufacturing facility have worker productivity and favorable workerergonomics at the forefront of design. Another advantage of the movablemanufacturing facility is the systems and production line approach tobuilding. Specific tasks are performed in each production line. With theaid of specialized equipment, worker tasks are made easier, more preciseand more time efficient all at the same time. The labor force can bemanaged such that workers are cross-trained to enable them to be movedfrom one production line to the next according to need. With the benefitof a controlled environment within the main structure of the movablemanufacturing facility, multiple shifts are not only possible, but easyto accommodate with equivalent productivity levels. This equates to aproduct of superior quality produced in less time than otherconstruction techniques.

[0077] The use of substantial hoisting devices in the movablemanufacturing facility reduces the labor content, speeds up themanufacturing process as well as enables the use of heretoforenontraditional structural concepts. One example of nontraditionalconstruction is the use of multi-story steel framing members to producemulti-story shear panel members presently unknown in the residentialconstruction industry. These multi-story metal or wood framing membersminimize the number of junctions among elements and with theircross-bracing and inherent dimensional stability, result in a structurewhose load-bearing walls have significantly greater integrity thanexisting “stick-built” methods. In addition, the tolerances are moreprecise and both labor and cost are significantly reduced.

[0078] The economic viability of the movable manufacturing facility is afunction of the efficiency with which it can produce the residentialstructures, since the efficiency must offset the cost of erecting themanufacturing facility at or near a particular housing development site.It is obvious that the benefit afforded by this manufacturing facilityis a function of the number of building sites being developed and thespeed with which these sites can be populated with standard sizeresidential structures. In addition, due to the speed of assembly of theresidential structures using this facility, it is not inconceivable thatthe one facility can be shared among a plurality of builders, whosedevelopment projects are co-located or nearby in the same generallocation.

[0079] The movable manufacturing facility represents a radically newapproach to building standard size homes on a large scale basis. Themovable manufacturing facility not only overcomes the problems inherentin the construction methods of the prior art, but also combines theadvantages of the three methods of dwelling construction identifiedpreviously. The result is that standard size homes can be builtsubstantially faster, with higher quality, lesser cost and moreefficiently than comparable homes built on-site by use of prior artconstruction methods.

BRIEF DESCRIPTION OF THE DRAWING

[0080]FIG. 1 illustrates a perspective view of the movable manufacturingfacility sited at a residential housing development;

[0081]FIG. 2 illustrates a perspective view of the movable manufacturingfacility with the roof removed therefrom;

[0082]FIG. 3 illustrates in plan view a typical overall layout of themovable manufacturing facility of the present invention;

[0083] FIGS. 4-8 illustrate typical implementations of the variousproduction lines contained in a typical embodiment of the movablemanufacturing facility which comprises a plurality of parallel orientedjuxtaposed production lines bounded by orthogonal alleys;

[0084] FIGS. 9-13 illustrate plan and side views of the portion of atypical standard size dwelling produced at each of the production linesof the movable manufacturing facility illustrated in FIGS. 4-8;

[0085]FIG. 14 illustrates a perspective view of the architecture of atypical transport element used in this manufacturing process and itsactual use to transport a standard size dwelling;

[0086]FIG. 15 illustrates a perspective view of a typical bent andhoisting element details;

[0087]FIG. 16 illustrates a perspective view of a typical integral baseframe used in the manufacturing process; and

[0088]FIG. 17 illustrates in perspective view a typical multi-storypanel implemented using steel framing members.

DETAILED DESCRIPTION

[0089] Glossary

[0090] The terms used in this description are defined below to ensurethat the proper import is ascribed to these terms and the usage of theseterms is therefore unambiguous.

[0091] Movable manufacturing facility—the facility described hereinwhich is used to produce standard size dwellings in an enclosed, climatecontrolled environment, which can comprise one or more enclosedstructures.

[0092] Dwelling—a structure(s), typically comprising either a singlefamily or multi-family home, which is used to house individuals.

[0093] Standard size dwelling—a dwelling which constitutes a “normal” orfull size dwelling, presently produced on-site by means of stickbuilding technology. This dwelling has an extensive range of design andfloor plan flexibility and includes both one and two story single ormulti-family structures.

[0094] Integral base frame—is that structural element which is integralto the base of a movable manufacturing facility produced standard sizehome, and provides the non-removable structural foundation upon whichthe vertical framing elements for the dwelling are attached. Theintegral base frame allows a standard size home to be created in itsentirety and moved prior to being located on a permanent foundation. Theintegral base frame is typically provided at the base of the outsidebearing perimeter walls, at interior load bearing walls, at selectedother locations and may be contained within a floor subassembly.

[0095] Manufactured home—a dwelling built in a factory environment andtransportable over public highways to a building site. These homesinclude trailer homes, modular homes and dwellings comprising aplurality of limited size segments that are transported to the buildingsite and which may be joined together.

[0096] Panelized home—a dwelling wherein a significant number ofcomponents representing a portion of the dwelling are fabricated in afactory environment, then transported over public highways to thebuilding site where they are assembled to form the basic structure.

[0097] Stick-built home—a dwelling built in the traditional manner ofusing dimensional lumber as framing members to fabricate the dwelling ona foundation at the building site according to a set of architecturalplans which have available an extensive range of design and floor planflexibility and includes both one and two story structures.

[0098] Manufacturing Facility Philosophy

[0099]FIG. 1 illustrates a perspective view of the typical movablemanufacturing facility 100, which is erected at a field location,proximate to a new community that is being constructed. The movablemanufacturing facility 100 can be disassembled and transported viatruck, and/or ship and/or rail, typically in containers for overseasapplication, for erection proximate to a residential housing developmentsite. FIG. 1 depicts a variety of the dwellings which can beconstructed, including single family detached homes S as well asthree-story multi-family units M, to illustrate the flexibility of theproduction capabilities of the movable manufacturing facility 100. Themulti-story dwellings M can be produced as a combination of a two-storycomponent with an overall floor area of a standard size dwelling, with asimilarly sized single story component produced for the third floor andplaced on top of the two-story component by a crane. As shown in FIG. 1,the movable manufacturing facility 100 is erected in close proximity toa large number of building sites B, some of which are shown in FIG. 1 ashaving residences sited thereon, others having foundationspre-constructed in place and others outlined as lots with noconstruction work having taken place.

[0100] The movable manufacturing facility 100 in the preferredembodiment disclosed herein comprises a substantially rectangularbuilding of sufficient size to encompass the dwelling productionoperation and of height to provide sufficient clearance for theconstructed dwelling, which is typically 30′-40′ in height. The movablemanufacturing facility has two large doorways in the end thereof 101,102, with a first doorway 101 as shown in FIG. 1 being on the leftmostside of the building and used to provide transport element ingress tothe movable manufacturing facility 100. A second large exterior door 102is located on the opposite side of the end wall of the building and isused to provide ingress to delivery vehicles which are providing the rawmaterials to a delivery alley, located within the movable manufacturingfacility, for the assembly of the residential structures that takesplace within the movable manufacturing facility 100. An optional thirddoor or doorway (not shown) can be provided substantially juxtaposed tothe second door to enable a second delivery pathway for either trucktraffic or rail traffic if a railroad siding is available at the site.Efficient bulk loads of materials necessary for the construction ofhomes are shown parked outside the movable manufacturing facility 100 ina temporary storage area ST prior to delivery into the delivery alley ofthe movable manufacturing facility 100 for unloading. An officestructure 104 is also illustrated in a typical location on the righthand side of the movable manufacturing facility 100 although the officestructure 104 need not be physically attached to the movablemanufacturing facility 100 or even a permanent structure. The officestructure 104 is where management, engineering, drafting, clerical andaccounting personnel are located to support the manufacturingactivities. As each lot in the development is sold and the home buyerdefines the model of the home to be placed thereon with the specificcustomized features desired by the buyer, this information is forwardedto the office area 104 of the movable manufacturing facility 100 where acomputerized control system schedules the construction of this dwelling,orders and coordinates the delivery of all necessary materials and,during the assembly phase of the dwelling, provides display informationto the workers at each stage of the assembly process to indicate thespecifics of this structure as defined by the initial user-providedorder.

[0101] By collapsing the linear structure of traditional residentialhousing production into a substantially volumetric process, andrelocating the partially completed structure from one production line ofthe movable manufacturing facility 100 to another, a significant amountof flexibility in the scheduling of the work can be attained byintermixing finished, roughed-in and feature work into concurrentlyextant operations within the same structure.

[0102] A completed standard size dwelling D can be seen in FIG. 1departing from the movable manufacturing facility 100 through an exitdoor 105 (FIG. 2) located on the far side of the movable manufacturingfacility 100. The exit door 105 is sized to enable the movement of thecompleted standard size dwelling D, mounted on the transport element tobe moved from the movable manufacturing facility. FIG. 1 alsoillustrates a completed standard size dwelling D traversing a paththrough the community to a building site B that has a foundation inplace and at which building site B a crane C awaits the arrival of thestandard size dwelling D. When the standard size dwelling D reaches thebuilding site B, the crane C is used to lift the completed standard sizedwelling D off the transport element T and to place the structure D onthe pre-existing foundation where it is secured in place. Alternatively,the pre-existing foundation can be a three-sided structure and thetransport element can enter the basement area of the foundation wherethe transport element can be removed from under the completed dwellingas the dwelling is set on the foundation.

[0103] The transport elements T shown in FIG. 1 typically comprise a“trailer” or “frame” that is equipped with a roadable apparatus, such assufficient number of axles and wheels to support the weight of thecompleted standard size dwelling D. The bed of the trailer T is ofextent great enough to securely support the completed standard sizedwelling D, which is built in stages on the transport element T as thetransport element T is moved from the ingress doorway 101 of the movablemanufacturing facility 100 to the egress doorway. A tow vehicle, such asa tractor, is used to move the transport element T and the completedstandard size dwelling D from the egress doorway of the movablemanufacturing facility 100 to the building site B and thence to returnthe transport element T to a parking area adjacent the movablemanufacturing facility 100 for use in a subsequent residential structureassembly. The community can be occupied in stages as the standard sizedwellings are manufactured and sited. Public access to the community istypically selected at a location distant from the movable manufacturingfacility 100, such that homes are sited from this juncture incrementallyto the movable manufacturing facility 100. The movable manufacturingfacility 100 makes use of temporary roadways R which are restricted frompublic use and are available to transport the completed standard sizedwellings D from the movable manufacturing facility 100 to the buildingsite B. As sections of the roadways R are filled with completed homes,these sections can be converted from restricted/controlled accessconstruction use to public use. The siting of the movable manufacturingfacility 100 is such in the particular environment illustrated in FIG. 1that the completed standard size dwellings D traverse roads R internalto the development and therefore do not have to contend with existingpublic roadways with their size and weight limitations, power lines,bridges and existing traffic. It is also possible to erect the movablemanufacturing facility 100 at a site that requires the use of existingpublic roads, which is feasible as long as the portions of the existingroadway that are used are free of obstructions and can be monopolizedduring the movement of a completed standard size dwelling D.

[0104] Movable Manufacturing Facility Architecture

[0105] The economic viability of the movable manufacturing facility 100is a function of the efficiency with which it can produce theresidential structures, since the efficiency must offset the cost oferecting the movable manufacturing facility 100 at a particular housingdevelopment site. It is obvious that the benefit afforded by thismovable manufacturing facility 100 is a function of the number ofbuilding sites B, the incremental cost savings associated with each unitmanufactured, and the speed with which these sites can be populated withresidential structures. In addition, due to the speed of assembly of theresidential structures using this facility, it is not inconceivable thatthe one movable manufacturing facility 100 can be shared among aplurality of builders, whose development projects are co-located ornearby in the same general location. The movable manufacturing facility100 achieves its efficiency by collapsing the linear, mutually exclusivebuilding trades operation of the prior art into an intensive volumetricfocus in the residential structure assembly process. This difference inassembly philosophy as well as the use of hoisting elements that areused in the movable manufacturing facility 100 provide the efficienciesand “automation” that assist in making this project cost-effective.Furthermore, the unique integral base frame that is used as theunderpinnings of each standard size dwelling D that is assembled notonly enables the completed structure to be constructed, transported, andplaced by a crane C but also provides a base for the standard sizedwelling D that is of greater stability and rigidity than existingmethods of manufacture. Finally, the movable manufacturing facility 100,with its hoisting elements, enables the use of a variety of framingtechniques and framing materials. These include western platformframing, balloon framing, the use of multi-story steel framing membersand the use of full height shear panel construction techniques that arepresently impractical to use in residential construction although theyprovide the benefits of increased structural integrity and reduced cost.Framing materials may include traditional dimension lumber, light gaugesteel products, heavier red iron steel and other cold rolled steelsections.

[0106] The movable manufacturing facility 100 is oriented as shown inthe preferred embodiment in FIG. 2 which is a perspective view of themovable manufacturing facility 100 with the roof removed therefrom. FIG.3 illustrates in plan view the layout of a typical movable manufacturingfacility 100, with icons pictured at the top of this figure to indicateto the reader the extent of completion of a standard size dwelling Dwithin each production line P1-P5. In this regard, the first productionline P1 produces an integral base frame which is positioned on atransport element T. The second P2 and third P3 production lines buildand subsequently relocate the preassembled panel subassemblies,including two-story high wall panels, onto the floor subassembly. Thefourth production line P4 produces and places a full size roofsubassembly onto the partitions previously produced and installed in thepartially completed standard size dwelling D. FIGS. 4-13 providedetailed plan views of the movable manufacturing facility 100 that isshown in perspective view in FIG. 2.

[0107] With reference to FIG. 2 and 3, the preferred embodiment of themovable manufacturing facility 100 shows the use of a plurality ofparallel oriented juxtaposed production lines P1-P5, each of which isused to create subassemblies and/or to provide warehousing of materialsthat are used in the construction process. Orthogonal to and aligned atone end of this plurality of production lines is a “delivery alley” DAthrough which the delivery vehicles pass to deliver the raw materialsthat are used in the standard size dwelling assembly process. Thedelivery alley DA typically extends the full length of the movablemanufacturing facility 100 and is of sufficient dimensions that deliveryvehicles can drive through the movable manufacturing facility 100 topark adjacent the production line which is the destination for thematerials provided by the delivery vehicle. A hoisting element H*integral to that production line P* is then able to quickly offload theraw materials from the delivery vehicle and the delivery vehicle thenexits the movable manufacturing facility 100 at an egress door 106distal from the ingress door 102 through which it entered the movablemanufacturing facility 100. Juxtaposed to and orthogonal to theplurality of production lines P1-P5 and at the end thereof opposite thedelivery alley DA is a dwelling assembly alley HA wherein the rawmaterials and subassemblies produced in each production line P* areassembled in an integrated manner into the standard size dwelling D.Each production line P* takes raw materials and either producessubassemblies that are lifted by the hoisting elements H* onto thestandard size dwelling D that is being assembled or provides awarehousing capability for the various raw materials that are used tocreate the standard size dwelling D. The specific details of eachproduction line P* are described below as an illustrative embodimentwith the specific implementation of each production line P* being amatter of design choice and somewhat dictated by the architecture of thestandard size dwellings D that are being assembled in the movablemanufacturing facility 100. Suffice it to say that each production lineP* is responsible for the complete construction of a volumetric sectionof the standard size dwelling D or is used to complete the finished workwithin the standard size dwelling D that has been largely completed atthe prior stages of the construction process.

[0108] It is evident that many variations of the layout illustrated inFIGS. 1-3 can be implemented, using the manufacturing techniques taughtherein. For example, the production lines may be construed asencompassing the section of the delivery alley adjacent to theproduction line and/or the production lines may be construed asencompassing the section of the dwelling assembly alley adjacent to theproduction line. The production lines may not be parallel oriented, andthe partially completed structure can exit a main section of themanufacturing facility to another assembly building, or another sectionof the manufacturing facility to have work performed thereon. Materialsstorage areas can also be positioned across the delivery alley, outsidethe manufacturing facility or in another dedicated portion of themanufacturing facility. These alternative configurations are simplyobvious variants of the basic configuration disclosed herein.

[0109] In the first production line P1, a floor subassembly is producedand loaded on the transport element T. The floor subassembly includes anintegral base frame which strengthens the floor subassembly to allow forthe construction, transportation and setting of the standard sizedwelling D on its foundation. In the second P2 and third P3 productionlines, continuing to the right from the first production line P1, largewall panels are framed, sheet rocked, finished, painted and inventoriedon racks prior to installation on the appropriate floor subassembly.Windows and doors are installed in the panelized wall subassemblies inthe second P2 and third P3 production line. In the fourth productionline P4, full size roof subassemblies are fabricated on the floor of themovable manufacturing facility 100 and then hoisted and placed on theframed partially completed standard size dwelling D by the bridge craneH4. Finish work, including panel joint finishing, cabinets, floorcovering, fixtures, etc., begins in the second production line P2,continues through the fourth production line P4 and is the primaryactivity implemented in the fifth production line P5.

[0110] A strategic accomplishment of the movable manufacturing facility100 is to provide a large scale factory in which multiple productionlines P* exist and which can be utilized to produce incremental aspectsof a standard size dwelling D. Some fundamental considerations are thatthe movable manufacturing facility 100 makes bulk materials available toall of the production lines P*, which capability is provided in theembodiment shown herein by the delivery alley DA, which serves all theproduction lines P*. A second consideration is that a plurality ofproduction lines P* are used, each of which produces a distinctincrement of the standard size dwelling D. A dwelling assembly alley HAis used to relocate the partially completed standard size dwelling Dfrom one production line P* to the next sequential production line P*typically via the transport element T on which the standard sizedwelling is constructed. A third consideration is the use of highcapacity hoisting elements H* in the production lines P* to allow forthe unloading and movement of bulk materials and for the constructionand handling of large subassemblies, including the installation of thesubassemblies in a partially completed standard size dwelling D.

[0111] Hoisting Elements

[0112] Efficiency of operation of the movable manufacturing facility 100is in part achieved through the use of hoisting elements H* that enablethe movement of large volumes of materials or large subassemblies thatare efficiently produced within the movable manufacturing facility 100.The hoisting elements H* minimize the hand labor since they are used topick and place raw materials, individual subassemblies, and to pre-stockmaterials, such as cabinets, flooring, plumbing fixtures, in thepartially completed standard size dwellings. As can be seen from theperspective view of FIG. 2, the movable manufacturing facility 100 inthe preferred embodiment is housed within a steel frame building thatuses a plurality of steel bents to support the roof as well as thehoisting elements H* that are part of the movable manufacturing facility100. The bents are aligned with the boundaries of each production lineP* and are of sufficient structural integrity to also support thehoisting elements H* and the loads which they service. The bents aretypically supported by a plurality of columns, located at regularintervals along the length of the bent, with a free span being providedacross the width of the dwelling assembly alley HA as well as thedelivery alley DA. For example, the dwelling assembly alley HA must bedimensioned to accommodate the full extent of the completely assembledstandard size dwelling D. These dimensions would typically be a 30-40foot floor to bent clearance and a support column to support column freespan of approximately 60 feet. The steel bent construction specifics ofsuch a building are well known and are not discussed in detail herein.The rails that support the hoisting elements H* are attached to thecolumns and can also be hung from the bents in the clear span area toprovide support for the rails where the span between columns is greaterthan otherwise would be allowable for the load bearing capacity of therails. There can be multiple hoisting elements H* in each productionline P*, with the hoisting capacity of these hoisting elements H* beingindividually sized to the task being performed in the associatedproduction line P*. The area of coverage by the hoisting elements H*within a production line P* can overlap so that each hoisting element H*has a sufficient range of travel to provide the greatest flexibility inuse in that production line P*, thereby enabling tasks to be performedby one hoisting element when the other hoisting element is occupiedperforming another task.

[0113]FIG. 15 illustrates in perspective view the implementation of atypical hoisting element H* that is used in a production line of themovable manufacturing facility 100. The hoisting element H* can be anyof a number of such devices known for the purpose, such as but notlimited to: boom type cranes, gantry cranes, hydraulic cranes, andtraveling floor cranes mounted on wheels or rails. For the preferredembodiment of the first production line P1 of the movable manufacturingfacility 100 disclosed herein the hoisting element is shown to be anoverhead traveling crane OC. The rails OCR1, OCR2 on which the overheadcrane OC ride are directly connected to the columns BC which support thetwo bents BB that delimit the boundaries of a production line (forexample, fourth production line P4) of the movable manufacturingfacility 100 and extend substantially the full length of the two bentsBB, so that the crane OC can traverse the entirety of the productionline P4 as well as either or both of the two adjoining alleys, deliveryalley DA, dwelling assembly alley HA.

[0114] Another one of the many possible embodiments of the enclosure isthe use of a fabric type of enclosure which fabric is stretched over aframework to enclose the work area. In this application, there is not aneed for bents and the hoisting elements H* can be free standingelements or connected to the columns.

[0115] First Production Line

[0116]FIG. 4 illustrates a typical plan view of the first productionline of the movable manufacturing facility 100, while FIG. 9 illustratesboth a plan view and a side view of a typical segment of the standardsize dwelling D that is assembled in the dwelling assembly alley HA as aresult of the work performed in the first production line P1 of themovable manufacturing facility 100. The first production line P1 of themovable manufacturing facility 100 is primarily used to create the floorsubassembly, which as a minimum includes the residential integral baseframe, and can also include the floor joist assembly and subflooring.The floor platform subassemblies are then typically placed on to thetransport element T that is positioned in the dwelling assembly alley HAjuxtaposed to one end of the first production line P1 of the movablemanufacturing facility 100.

[0117] The equipment and work areas of the first production line P1comprise a number of raw material processing stages. In particular,standard lengths of the integral base frame beams and floor joists aredelivered by truck or rail to the delivery alley DA and the hoistingelement H1 of the first production line P1 moves these raw materialsfrom the delivery vehicle to storage bins or racks 401, 402 locatedwithin the first production line P1. For example, 40 foot lengths ofintegral base frame beams are noted in FIG. 4, although other lengths asrequired can be used. Associated with each storage area 401, 402 is asaw station 403, 404 that is used to cut where necessary the rawmaterial into the required lengths. The cut stock is then stockpiled infinished material storage racks 405, 406. For example, the cut beams arestored in cut frame storage 405 while the cut floor joists are placedinto the finished floor joist storage 406. Preferably, the amount ofcutting is kept to a minimum by the pre-architected layout of the firstfloor subflooring and integral base frame.

[0118] An integral base frame assembly production line 411 is includedin the first production line P1 and is described in additional detailbelow. The partially assembled integral base frames are transported fromthe integral base frame assembly production line 411 by the overheadcrane H1 and placed on the first stage floor platform assembly 412table. The floor joist table 413 is used to create a subassembly offloor joists, with insulation, wiring, plumbing installed therein andthe overlay of floor sheathing, obtained from the floor sheathingstorage rack 414, installed thereon. The overhead crane H1 transportsfloor joist subassemblies from the floor joist table 413 to the firststage floor platform assembly table 412 to be placed within thepartially assembled frame. The frames, with floor joist subassembliesinstalled therein are then “capped” and transported by the overheadcrane H1 to the dwelling assembly alley HA where they are placed on thetransport element T in a predetermined position and interconnected withother (if any) frames produced to create a complete floor subassembly.

[0119] Transport Element

[0120]FIG. 14 illustrates in perspective view a typical transportelement T that is used to support the standard size dwelling D (as shownin FIG. 14) as it is assembled in the movable manufacturing facility 100and transported from this facility to a permanent site. The transportelement T, as shown in a typical embodiment in FIG. 14, comprises arectangular frame formed of a plurality of rigid interconnectedsupporting members T1-T5. A number of the supporting members T1-T4 formthe substantially rectangular exterior frame and the remainingsupporting member T5 forms an interior supporting member. A standardsize dwelling is shown in dotted line outline form placed on thetransport element T to illustrate the size and extent of the transportelement T with respect to a standard size dwelling. The typicalsupporting members T1-T5 are shown as steel I-beams of sufficientcapacity to support the full size dwelling. Three of the supportingmembers T1, T3, T5 are shown equipped with wheel assemblies W to therebyenable the transport element T to be repositioned within the movablemanufacturing facility 100 and thence to the building site for thestandard size dwelling placed on the transport element. FIG. 14 alsoillustrates a towing hitch PH affixed to one end of the substantiallyrectangular frame formed of supporting members T1-T5 to thereby enable atow vehicle to connect to the transport element T and perform thetransportation function.

[0121] It is obvious that a number of alternative embodiments of thetransport element T can be devised, such as having axles span the entirewidth of the transport element, as a function of the performancecharacteristics required for the specific implementation of the movablemanufacturing facility 100 as well as the nature of the path that thetransport element may take to the building site. It is also envisionedthat the wheel assemblies W can be made removable from the frame formedof supporting members T1-T5. Thus, it is possible that the transportelement can comprise the integral base frame FF of the structure itself,with the wheel assemblies W initially installed thereto to facilitatethe movement of the standard size dwelling through the manufacturingprocess and delivery to the building site. Once installed at thebuilding site, the standard size dwelling no longer requires the wheelassemblies W, and these can be removed for reuse in the manufacturing ofanother standard size dwelling. Also, the wheel assemblies W can beinterchanged so that a separate set is used to move the standard sizedwelling D to the building site. The wheel assemblies W may also bedispensed with in the factory if the foundation frame is used as part ofa rail system.

[0122] Integral Base Frame Architecture

[0123] The integral base frame is that structural element which isintegral to the base of a movable manufacturing facility producedstandard size home, and provides the non-removable structural foundationupon which the vertical framing elements for the dwelling are attached.The integral base frame allows a standard size home to be created in itsentirety and moved prior to being located on a permanent foundation. Theintegral base frame is typically provided at the base of the outsidebearing perimeter walls, at interior load bearing walls, at selectedother locations and may be contained within a floor subassembly.

[0124] The function of the integral base frame can be seen when anexisting home is moved from one location to another. In this situation,the existing home is gently lifted off its permanent foundation, usuallyby means of jacks. At this point, a base frame is temporarily insertedunder the perimeter and load bearing interior walls to support themthereby permitting the entire structure to be carefully moved on to twosupport beams without the benefit of a permanent foundation. In themovable manufacturing facility, the standard size home is built with anintegral base frame to enable the simple relocation of the partiallybuilt home within the movable manufacturing facility and eventually to apermanent foundation at the home site. The home can also be later movedwithout significant complexity, since the structure incorporates theintegral base frame and can be relocated to another permanentfoundation.

[0125] Thus, the standard size home built in the movable manufacturingfacility is substantially built “in space” rather than “in place”. Forthis to be possible, the initial step in the manufacturing processrequires the use of the integral base frame which establishes a solidpoint of beginning and provides a dimensionally stable foundation. Theintegral base frame thereby provides structural integrity to the base ofthe movable manufacturing facility manufactured home, which enables thehome to exist in space without continuous additional support to enablethe standard size home to be manufactured, transported and placed on apermanent foundation as an integral, self-supporting and rigidizedstructure. The integral base frame distributes vertical loads downwardfrom the wall sections to the transport element and upward from thetransport element to the load bearing walls. The integral base framealso provides a dimensionally stable flat surface on which the wallelements can be added and can be manufactured from light gauge steel,wood, concrete, plastic, or other suitable materials.

[0126] Integral Base Frame Assembly

[0127]FIG. 16 illustrates in perspective view a typical architecture ofthe integral base frame assembly FF that is used in the standard sizedwelling manufacturing process. In particular, the integral base frameFF is the element that circumscribes the entirety of the standard sizedwelling D and provides the support and stability to enable the entirecompleted structure to be relocated by a crane C from a transportelement T to the preassembled foundation at the building lot B. In orderto accomplish this function, the integral base frame FF comprises a setof steel beams, such as I-beams, that are assembled into a frameworkthat conforms to the foundation. The I-beams, as shown in FIG. 16, areassembled by welding together to form a framework into which a floorjoist assembly FJ can be fabricated. This process is effected by theoverhead crane H1 transporting the partially assembled integral baseframe FF from the frame assembly area 411 to the first stage floorplatform assembly table 411. The overhead crane H1 then lifts acompleted floor joist subassembly, from the floor joist table 413 andrelocates the subassembly to the first stage floor platform assemblytable 412 where it is inserted into the partially assembled integralbase frame FF. Additional precut I-beams are then transported by theoverhead crane H1 from the storage racks 405 to the first stage floorplatform assembly table 412 where they are positioned to cap the openends of the partially assembled integral base frame FF and complete anentire section of the floor subassembly. The joists FJ are secured tothe integral base frame FF via welds at points where one of the steeljoists FJ meet a corresponding point of the integral base frame FF. Thedimensions of the integral base frame FF and the joists FJ arepreferably selected so that the joists snugly fit within the “pocket”created by the cross-section of the integral base frame elements and thecapped integral base frame FF creates a resultant dimensionally stableand rigid floor subassembly. The floor sheathing FS, as shown in FIG.16, is placed to expose a length of the joists FJ sufficient to fitwithin the pocket provided by the integral base frame FF, so theassembled floor subassembly does not include any voids between the floorsheathing FS and the integral base frame FF. The floor sheathing FS canbe of dimensions greater than typically used since the hoisting elementH1 can be used to transport these materials.

[0128] Second Production Line

[0129]FIG. 5 illustrates a typical plan view of the second productionline P2 of the movable manufacturing facility 100, while FIG. 10illustrates both a plan view and a side view of a typical segment of thestandard size dwelling D that is assembled in the dwelling assemblyalley HA as a result of the work performed in the second production lineP2 of the movable manufacturing facility 100. The second production lineP2 of the movable manufacturing facility 100 is primarily used tofabricate the exterior walls and first floor interior walls of thestandard size dwelling D.

[0130] The equipment and work areas of the second production line P2comprise at least one raw material processing stage. The raw materialsused to perform the framing function can be selected from the class ofelements including, but not limited to: wood, steel, compositionmaterials. For the purpose of illustrating the operation of thepreferred embodiment of the movable manufacturing facility 100, steel isdescribed as the element used for framing the interior and exteriorwalls. In particular, standard lengths of raw steel framing members aredelivered by truck or rail to the delivery alley DA and the hoistingelement H2 (or multiple hoisting elements) of the second production lineP2 moves these raw materials from the delivery vehicle to storage binsor racks 501, 506, 507 located within the second production line P2. Forexample, 20 foot lengths of framing members can be used, although otherlengths as required can be used. Associated with each storage area 501is a saw station 502 that is used to cut where necessary the rawmaterial into the required lengths. The cut stock is then stockpiled infinished material storage racks 503. Preferably, the amount of cuttingis kept to a minimum by the pre-architected layout of the exterior wallsand first floor interior walls.

[0131] A wall panel assembly production line is included in the secondproduction line P2. At least one stud table 504, 505 is provided tocreate a subassembly of an exterior or interior wall, with insulation,wiring, plumbing, windows, doors installed therein as desired. Theoverhead crane H2 transports wall panel assemblies from the stud table504, 505 to the work platform 509 where movable scaffolding is used toenable the workers to finish the wall subassemblies. The movablescaffolding enables the workers to move with respect to the wallsubassembly and tape drywall seams, finish the drywall, and paint thewall subassembly. The finished wall subassembly is then relocated to thestorage racks 508 of the second production line P2 (as also shown inperspective view on the left side of FIG. 15) or directly placed inposition and secured in the dwelling D being assembled in the dwellingassembly alley HA, as also shown in part in FIG. 16. If thepremanufactured panels are first stored in the storage racks 508, thepremanufactured panels are later transported by the overhead crane H2 tothe dwelling assembly alley HA where they are placed on the floorsubassembly, which was installed on the transport element T at the firstproduction line P1 of the movable manufacturing facility 100, in apredetermined position and interconnected with other wall subassembliesto create a complete framed and subfloored structure assembly.

[0132] The exterior finish may not be present on the exterior walls tothereby enable the workers to access the various utilities that are runthrough the walls. As wall segments are joined, the utilitiespre-installed therein must be interconnected, and this can be done viaaccess from the exterior (or top) of the wall, rather than the interioras is presently done. The multitude of subsystems that comprise adwelling are treated as an integrated system with the progression ofconstruction of each subsystem coordinated with the various othersystems to ensure coherent construction of the dwelling in an efficientmanner.

[0133] At this juncture, to increase the speed of manufacture, reducethe handling of materials, cabinet assemblies, doors, windows, floorcoverings etc. (from rack 506) are prestocked in the shell of thestandard size dwelling D. The prestocking enables the workers at laterstages of assembly to have the necessary materials already situatedwithin the standard size dwelling D, via crane H*, to enable the workersto perform finish work concurrently with the second story and the roofbeing assembled and installed on the standard size dwelling D. Thematerials, such as drywall, can be of dimensions greater than typicallyused since the hoisting element H2 can be used to transport thesematerials, rather than depending on the workers to handle each pieceindividually, with the size of the materials being dictated by thephysical limitations of the workers.

[0134] Third Production Line P3

[0135]FIG. 6 illustrates a plan view of a typical third production lineP3 of the movable manufacturing facility 100, while FIG. 11 illustratesboth a plan view and a side view of a typical segment of the standardsize dwelling D that is assembled in the dwelling assembly alley HA as aresult of the work performed in the third production line P3 of themovable manufacturing facility 100. The third production line P3 ispredicated on the presumption that the standard size dwelling beingmanufactured is a two story dwelling. Obviously, if one story dwellingsare being manufactured, the third production line P3 as described hereinmay be deemed to be unnecessary.

[0136] The equipment and work areas of the third production line P3 aresimilar to those of the second production line P2 and comprise at leastone raw material processing stage. In particular, standard lengths ofraw steel framing members are delivered by truck or rail to the deliveryalley DA and the hoisting element H3 of the third production line P3moves these raw materials from the delivery vehicle to storage bins orracks 601, 606, 607 located within the third production line P3. Forexample, 20 foot lengths of framing members can be used, although otherlengths as required can be used. Associated with each storage area is asaw station 602 that is used to cut where necessary the raw materialinto the required lengths. The cut stock is then stockpiled in finishedmaterial storage racks 603. Preferably, the amount of cutting is kept toa minimum by the pre-architected layout of the exterior walls and secondfloor interior walls.

[0137] A floor and wall panel assembly production line is included inthe third production line P3. At least one stud table 604, 605 isprovided to create a subassembly of the first floor ceiling/second storyfloor, exterior or interior walls, with insulation, wiring, plumbinginstalled therein. The overhead crane H3 transports floor and wall panelassemblies from the stud table 604, 605 to the work platform 609 wheremovable scaffolding is used to enable the workers to finish the wallsubassemblies. The movable scaffolding enables the workers to move withrespect to the wall subassembly and tape drywall seams, finish thedrywall, and paint the wall subassembly. The finished wall subassemblyis then relocated to the storage racks 608 of the third production lineP3 (as shown in perspective view on the left of FIG. 15) or directlyplaced in position in the dwelling being assembled in the dwellingassembly alley HA. If the premanufactured wall panels are first storedin the storage racks 608, the premanufactured wall panels are thentransported by the overhead crane H3 to the dwelling assembly alley HAwhere they are placed on the preassembled first floor, which wasinstalled on the transport element T at the second production line P2 ofthe movable manufacturing facility 100, in a predetermined position andinterconnected with the exterior and first story interior wall panels tocreate a completely enclosed framed and subfloored single storystructure assembly. The second floor premanufactured wall panels arethen transported by the overhead crane H3 to the dwelling assembly alleyHA where they are placed on the framed single story structure tocomplete the framing of the second story. At this juncture, to reducethe labor required, cabinet assemblies, doors, windows, etc. (in rack606) are “prestocked in the second story of the shell of the standardsize dwelling D. The prestocking enables the workers at later stages ofassembly to have the necessary materials already situated within thestandard size dwelling D, via crane H3, to enable the workers to performfinish work concurrently with the roof being assembled and installed onthe standard size dwelling D. The materials, such as drywall, can be ofdimensions greater than typically used since the hoisting element H3 canbe used to transport these materials, rather than depending on theworkers to handle each piece individually, with the size of thematerials being dictated by the physical limitations of the workers.

[0138] Fourth Production Line P4

[0139]FIG. 7 illustrates a plan view of a typical fourth production lineP4 of the movable manufacturing facility 100, while FIG. 12 illustratesboth a plan view and a side view of the segment of the standard sizedwelling D that is assembled in the dwelling assembly alley HA as aresult of the work performed in the fourth production line P4 of themovable manufacturing facility 100. In addition, FIG. 15 illustrates anend view of a typical fourth production line P4. The fourth productionline P4 of the movable manufacturing facility 100 is primarily used tofabricate, relocate and install the roof subassembly of the standardsize dwelling D.

[0140] The equipment and work areas of the fourth production line P4comprise at least one raw material processing stage. In particular,standard lengths of raw steel framing members and roof truss members aredelivered by truck or rail to the delivery alley DA and the hoistingelement H4 of the fourth production line P4 moves these raw materialsfrom the delivery vehicle to storage bins or racks 701 located withinthe fourth production line P4. For example, 20 foot lengths of framingmembers can be used, although other lengths as required can be used.Associated with each storage area is a saw station 702 that is used tocut where necessary the raw material into the required lengths. The cutstock is then stockpiled in finished material storage racks 703.Preferably, the amount of cutting is kept to a minimum by thepre-architected layout of the roof.

[0141] A roof subassembly production line is included in the fourthproduction line P4. A roof truss jig 704 is provided to enable theworkers to produce the required roof trusses which are then moved byhoisting element H4 to the roof subassembly fabrication areas 707 tocreate an entire roof subassembly. The drywall materials are retrievedfrom drywall storage area 705 and positioned in the pattern that isrequired for the finished area of the ceiling that lies under the roof.The drywall is then adhesively secured to the roof trusses when theseelements are positioned on the drywall that is in place on the roofsubassembly fabrication areas 707. The roof construction then proceedswith the required roof sheathing, etc until the entire roof subassemblyis completed. The roof subassembly is then hoisted into place on top ofthe framed shell of the two story structure and thus must be constructedsomewhat differently from existing roof designs. In particular, sincethe crane H4 “picks and places” the entire roof subassembly, the trussesused to fabricate the roof subassembly must be designed to support bothdynamic and static traditional roof loads, supported by the frame of thehouse, as well as to be capable of supporting the weight of theassembled roof when supported from the ridge line as it is beinghoisted. Therefore, the roof trusses must be designed to account forcompression and tension loads in both directions. The overhead crane H4(termed OC in FIG. 15) transports the completed roof subassembly fromthe roof subassembly fabrication areas 707 to the dwelling assemblyalley HA where it is placed on the framed structure, which was installedon the transport element T at the first P1 through third P3 productionlines of the movable manufacturing facility 100, in a predeterminedposition and interconnected with the interior and exterior wallproduction lines to create a complete enclosed standard size dwelling D.

[0142] The fabrication of the roof subassembly on the roof subassemblyfabrication areas 707 results in a reduced assembly time, since workingon ground level is easier, safer and more efficient than constructingthe roof in place on the framed two story dwelling as is presently donein the stick building technology.

[0143] Fifth Production Line P5

[0144]FIG. 8 illustrates a plan view of a typical fifth production lineP5 of the movable manufacturing facility 100, while FIG. 13 illustratesboth a plan view and a side view of a typical segment of the standardsize dwelling D that is assembled in the dwelling assembly alley HA as aresult of the work performed in the fifth production line P5 of themovable manufacturing facility 100. In particular, the fifth productionline P5 of the movable manufacturing facility 100 is used to perform allremaining finish work that was not completed in the previousmanufacturing stages. In this regard, the fifth production line P5 maynot strictly be termed a production line since no subassembly isproduced therein, but instead, in the preferred embodiment of themovable manufacturing facility 100, it is used as a storage and stagingarea where the prestocking materials, such as floor covering, are storedand cut to size for transportation to the appropriate production linefor insertion into the partially competed dwelling located in thedwelling assembly alley HA, as described above. Therefore, the finishwork includes any remaining painting, installation of plumbing fixtures,electrical outlets, trim work, appliance installation, etc. Additionalexterior work that was not previously completed is now done, such asgutters, roofing, flashing, exterior trim painting, etc. The materialsfor these activities can be stored in a plurality of rows of high baystorage racks 801-804 as shown in perspective view on the right handside of FIG. 15. The materials handled in the fifth production line P5of the movable manufacturing facility 100 may be more adapted toprocessing using a forklift truck rather than an overhead crane H*. Inaddition, the delivery alley DA may include a number of externaloverhead doors in traditional loading dock style to enable the rapidunloading of many enclosed delivery vehicles, each of which may delivera small quantity of materials, when compared to the deliveries processedat the other production lines P1-P4 of the movable manufacturingfacility 100. Furthermore, the dwelling assembly alley HA may not becontiguous with the fifth production line P5, since there is notnecessarily any relocation of large bundles of materials to the dwellingat this stage of production. Therefore, the dwelling can even be movedat this juncture to a section of the building remote from the productionlines P1-P5, or “off-site” external to the building to another enclosedstructure, or even in an open area outside.

[0145] Additional Features

[0146] It is evident that the delivery alley DA can include a storagearea, located across the delivery alley DA from the production lines.The materials storage is a function of the proportion of just-in-timedeliveries that can be scheduled for the movable manufacturing facility100. It is evident that the storage areas must be sized as a function ofthe materials fragility, volume of construction activity, and delaysexpected in the delivery of raw materials. Thus, weather imperviousmaterials, such as roofing material and structural steel can be storedexternal to the movable manufacturing facility and moved in place intothe production lines by forklift or even a hoisting element that isintegral to the delivery alley DA. Furthermore, the fifth productionline P5 includes a flooring storage area in the above-describedembodiment, and the flooring material is cut and then transported byforklift to the second and/or third production lines P2, P3 as requiredto preload the first and second floor of the partially completeddwelling prior to the respective ceilings being placed on the partiallycompleted dwelling, thereby enclosing that particular volume of thedwelling. The use of the integral hoisting elements H* also enables theuse of atypical size and weight materials. The sheet rock, roofsheathing, exterior wall sheathing and subflooring can be in 6′*16′ or8′*16′ sizes, which are impossible for workers to handle by hand, butare well within the capability of the hoisting elements. The use of thissize materials minimizes the number of seams in the wall, ceiling andfloor subassemblies, thereby reducing finishing labor and providingadditional rigidity to the resultant dwelling.

[0147] Furthermore, two-story wall subassemblies can be manufacturedusing the steel framing materials described herein. FIG. 17 illustratesa perspective view of a typical two-story wall panel subassembly thatcan be manufactured using the facilities described herein. Inparticular, the two-story wall panel subassembly is constructed to beplaced on and secured to the floor subassembly, and is preconfigured toreceive the joists for the second floor flooring. As shown in thisfigure, the entire two-story subassembly can be hoisted and transportedas an integral unit.

[0148] Summary

[0149] The benefits of the movable manufacturing facility 100 are thatthere is concurrent and/or overlapping construction of majorsubassemblies of the standard size dwelling D in the various productionlines P1-P5 of the movable manufacturing facility 100. The completedsubassemblies from production lines P1-P4 are then assembled in thedwelling assembly alley HA in assembly line fashion as the standard sizedwelling D reaches that production line P* of the movable manufacturingfacility 100. For example, the second floor walls can be manufactured inthe third production line P3 of the movable manufacturing facility 100while the floor subassembly and first floor walls are being built andassembled in the first and second production lines P1, P2 of the movablemanufacturing facility 100. The second story ceiling can be manufacturedin the fourth production line P4 of the movable manufacturing facility100. In addition, the roof can be concurrently under way or initiated inthe fourth production line P4 of the movable manufacturing facility 100while the standard size dwelling D is located at the third productionline P3 of the movable manufacturing facility 100 for installation ofthe second story floor and walls. The temporal coordination of thevarious stages of work can be dynamically adjusted as a function ofmaterial availability as well as construction progress at previous andsubsequent production lines of the movable manufacturing facility 100.The shear panels can be manufactured and stockpiled at the second P2 andthird P3 production lines of the movable manufacturing facility 100, andthe workers can move between production lines P* as the changing needsof the assembly process dictate. In addition, there are no delaysoccasioned by ambient weather conditions, and significantly reducedwaste due to the “automated” method of manufacturing.

[0150] The standard size dwellings produced in this movablemanufacturing facility represent significant advances from what isproduced by the housing industry today. It is achieved by collapsing thetraditional sequential building process into a small finite number ofsteps, each of which is implemented in a predetermined production lineof the facility somewhat independent of, yet in close coordination with,the building activity that takes place in the other production lines ofthe facility. This allows, for instance, a house's roof and floor to beassembled at the same time, yet on different production lines. Onceindividual components are pre-assembled, they are affixed, eitherdirectly or indirectly, to the rigidized integral base frame as itadvances through the dwelling assembly alley. This final assembly of thehousing components occurs in a very short period of time. Quality isassured by virtue of a controlled work environment within the movablemanufacturing facility, factory tolerances, a streamlined, repetitivelabor task assembly process, etc. The sequential, mutually exclusive anddisjunct subcontractor operations of the prior art are replaced with apartitioning of the construction process to functionally complete theconstruction of predetermined volumetric sections of the structure ateach of the production lines as the dwelling progresses through themovable manufacturing facility. Thus, wall sheathing and finishing maybe started earlier than in the traditional stick-built building processwhile some operations, such as electrical and plumbing, can be done fromthe exterior of the dwelling when interior walls are in place. Eachdwelling exits the movable manufacturing facility as a substantiallycompleted “turn key” standard size dwelling ready for occupancy. Theseexamples are indicative of a streamlined and efficiency driven approachto dwelling construction, which makes use of a factory environment torevolutionize the dwelling construction process for standard size homes.

We claim:
 1. A dwelling comprising: a) a plurality of exterior walls,each such plurality of exterior walls having a length, and b) a metallicintegral base frame, non-removable from and fixedly attached to andalong at least a portion of the length of each of said plurality ofexterior walls.
 2. The dwelling of claim 1 further including at leastone load-bearing interior wall and wherein the at least one load-bearinginterior wall each has a length and said integral base frame is fixedlyattached to the length of each of said at least one load-bearinginterior wall.
 3. The dwelling of claim 1 wherein said metallic integralbase frame is comprised of connected beams.
 4. The dwelling of claim 3wherein said connected beams comprise I-beams.
 5. The dwelling of claim3 wherein said connected beams are welded to form said metallic integralbase frame.
 6. The dwelling of claim 4 wherein said I-beams are weldedto form said metallic integral base frame.
 7. The dwelling of claim 1further including a floor assembly fixedly attached to said integralbase frame.
 8. The dwelling of claim 7 wherein said floor assemblysurrounds said integral base frame.